System and method for hot wire arc steering

ABSTRACT

The invention described herein generally pertains to a system and method related to influencing a direction of an arc within a welding operation. Within a hot wire welding operation, an arc is generated between an electrode and a workpiece and a welding wire is energized while being supplied to a puddle formed by the electrode in order to deposit the liquefied welding wire onto the workpiece. A welder system and/or method is provided that controls a direction of the arc based on at least one of a polarity of the welding wire (via a power supply that energizes the welding wire), a location of the welding wire in proximity to the arc, a synchronization and/or de-synchronization of a polarity of the welding wire with the electrode, an activation and/or a de-activation of energizing of the welding wire, or a combination thereof.

PRIORITY

This application claims the benefit of priority to U.S. ProvisionalApplication Ser. No. 61/839,629, filed Jun. 26, 2013, and entitled“SYSTEM AND METHOD FOR HOT WIRE ARC STEERING.” The entirety of theaforementioned application is incorporated herein by reference.

TECHNICAL FIELD

In general, the present invention relates to an orbital welding systemor a non-orbital welding system. More particularly, the presentinvention relates to a controlling a direction of an arc in a weldingoperation with at least one of a current or a welding wire location inproximity to the arc.

BACKGROUND OF THE INVENTION

Welding systems reside at the core of the modern industrial age. Frommassive automobile assembly operations to automated manufacturingenvironments, these systems facilitate joining in ever more complicatedmanufacturing operations. Hot wire welding processes a wire or electrodebeing heated (e.g., via current) and received by a puddle created by amain heat source (e.g., plasma arc, tungsten inert gas (TIG) welding,metal inert gas (MIG) welding, flux core, among others). The hot wirewelding process includes the resistance heating of the up to or near amelting point of such wire. In hot wire welding processes, the formationof an arc is avoided since an arc condition disrupts or overheats thepuddle. A wire heated near or close to the melting point of the wirewithout arcing events is received by the puddle with little or nodisruption. In order to prevent a formation of an arc, a weldingparameter related to the workpiece can be detected. The weldingparameter can indicate an arc condition in which the hot wire weldingprocess can be adjusted.

Additionally, welding may involve, raising, cladding, building up,filling, hard facing, overlaying, joining, and other weldingapplications. When confronted with a workpiece having a curved surface,an orbital welding processes may be used to rotate the welding head toapply a weld to the curved surface. The most common examples, whereorbital welding is used, is the welding of pipe. Pipe welding mayinclude thin wall application where the welding head is rotated aboutthe other surface two piece ends being joined together, alternatively,pipe welding may include deep grove geometries where the weldingelectrode extends into a grove formed between the two pipes being joinedto lay down successive beads of weld material to fill the grove the jointhe thick walled pipes. Orbital welding systems may include a weldinghead that is mounted on a guide track or a fixture that clamps or isotherwise supported on the workpiece and rotated to supply a weld. Withorbital welding often involves limited visibility of a welding zone withlead cameras and/or trailing cameras.

Fusion into a sidewall of a joint or a more narrow “V” groove can leadto pockets of a lack of material (e.g., weld deposit) that should beexistent therein. These pockets require repair by grounding out or beingre-welded. In either of orbital welding systems or non-orbital weldingsystems, lack of fusion, among other welding defects, requires repairwhich can add costs to a welding job as well as an increase in time forwelding job completion. Lack of fusion can be defined as the pooradhesion of a weld bead to a base metal and incomplete penetration is aweld bead that does not start at a root of a weld groove. Further,welding techniques are attempting to minimize the total amount ofwelding by decreasing a width of a joint (e.g., more narrow “V” groove)which translates into a steeper sidewall. A steeper sidewall is harderto penetrate into during a welding operation.

Orbital welding systems and non-orbital welding systems can becompromised by the deep grove geometries steeper sidewalls with aworkpiece and what is needed is an improved technique to related topreventing lack of fusion during a welding operation.

SUMMARY OF THE INVENTION

In accordance with an embodiment of the present invention, a weldersystem is provided that includes a welding torch that includes anelectrode adapted to form a weld joint on a workpiece. The welder systemfurther includes a power source that creates an arc between theelectrode and the workpiece. The welder system includes a wire feederthat is connected to a supply of welding wire to provide a welding wireto the arc, wherein the arc is a first polarity. The welder systemincludes a welding wire power supply that energizes the welding wirewith at least one of the first polarity or a second polarity therebyinfluencing a direction of the arc. The welder system includes acontroller that influences the direction of the arc with at least one ofa strength or a polarity of the energized welding wire via the weldingwire power source, wherein a magnitude of the direction is controlled bya magnetic field of the welding wire and the magnetic field iscontrolled by a current in the welding wire via the welding wire powersource.

In accordance with an embodiment of the present invention, a method isprovided that includes at least the steps of creating an arc between anelectrode and a workpiece; delivering a welding wire to the arc;energizing the welding wire with a current; and utilizing a polarity ofthe current to change a direction of the arc.

In accordance with an embodiment of the present invention, a weldersystem is provided that includes at least the following: an orbitalwelder having a chassis supported adjacent to a workpiece; a weldingtorch coupled to the chassis that includes an electrode adapted to forma weld joint on a workpiece; a power source that creates an arc betweenthe electrode and the workpiece; a wire feeder that is connected to asupply of welding wire to provide a welding wire to the arc, wherein thearc is a first polarity; means for energizing the welding wire with atleast one of the first polarity or a second polarity thereby influencinga direction of the arc; means for influencing at least one of thedirection of the arc or a magnitude of the arc with at least one of astrength or a polarity of the energized welding wire; and means foradjusting a location of the welding wire in proximity to the arc.

These and other objects of this invention will be evident when viewed inlight of the drawings, detailed description and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangementsof parts, a preferred embodiment of which will be described in detail inthe specification and illustrated in the accompanying drawings whichform a part hereof, and wherein:

FIG. 1 illustrates a front view of an orbital welding system;

FIG. 2A illustrates a side view of an orbital welding system;

FIG. 2B illustrates a perspective view of an orbital welding system;

FIG. 3A is a diagram illustrating portion of a hot wire welding system;

FIG. 3B is a diagram illustrating portion of a hot wire welding system;

FIG. 4 is a diagram illustrating a welder system that manipulates an arcdirection;

FIG. 5A is a side view of a welding operation that influences adirection of an arc;

FIG. 5B is a top view of a welding operation that influences a directionof an arc;

FIG. 6A is a side view of a welding operation that influences adirection of an arc;

FIG. 6B is a top view of a welding operation that influences a directionof an arc;

FIG. 7A is a side view of a welding operation that influences adirection of an arc;

FIG. 7B is a top view of a welding operation that influences a directionof an arc; and

FIG. 8 is a flow diagram of controlling a direction of an arc in awelding operation based on a polarity of current that energizes awelding wire.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the invention relate to methods and systems that relateto influencing a direction of an arc within a welding operation. Withina hot wire welding operation, an arc is generated between an electrodeand a workpiece and a welding wire is energized while being supplied toa puddle formed by the electrode in order to deposit the liquefiedwelding wire onto the workpiece. A welder system and/or method isprovided that controls a direction of the arc based on at least one of apolarity of the welding wire (via a power supply that energizes thewelding wire), a location of the welding wire in proximity to the arc, asynchronization and/or de-synchronization of a polarity of the weldingwire with the electrode, an activation and/or a de-activation ofenergizing of the welding wire, or a combination thereof.

“Welding” or “weld” as used herein including any other formatives ofthese words will refer to depositing of molten material through theoperation of an electric arc including but not limited to submerged arc,GTAW, GMAW, MAG, MIG, TIG welding, or any electric arc used with anorbital welding system.

The best mode for carrying out the invention will now be described forthe purposes of illustrating the best mode known to the applicant at thetime of the filing of this patent application. The examples and figuresare illustrative only and not meant to limit the invention, which ismeasured by the scope and spirit of the claims. Referring now to thedrawings, wherein the showings are for the purpose of illustrating anexemplary embodiment of the invention only and not for the purpose oflimiting same, FIGS. 1-7 illustrates a welding system that is used withan automated or semi-automated welding system. One illustrative exampleof a welding system is orbital welding, which is often used for thejoining of tubes or pipes of various types of materials. For example, aTungsten Inert Gas (TIG) or Gas Tungsten Arc Welding (GTAW) weldingtorch may be used to orbit around the pipes to be welded together by anautomated mechanical system. FIGS. 1-2B illustrates an exampleembodiment of orbital welding system 100 (also referred to as welder,system, welding system, and/or welder system) as used in an orbitalwelding environment. Orbital welding system 100 includes a weldingtractor (not shown) that travels around the pipes or tubes, a weldingpower source (not shown) and controller (not shown), and a pendant (notshown) providing operator control. It is to be appreciated that thesubject innovation can be used with any orbital or non-orbital weldingsystem. Moreover, the subject innovation can be used with any weldingoperation that includes an arc and a hot wire that is liquefied todeposit welding material onto a workpiece.

System 100 (as seen in FIGS. 1-2B) is generally used in deep groovewelding. In the example shown, welding system 100 includes an orbitalTIG welder having a welder body or chassis 101, which may be attached tothe work piece or supported on a track. Welder 100 includes a weldingtorch, generally indicated at 30, having a welding electrode 32 fordepositing weld material to form a weld joint at welding zone Z.Electrode 32 is an extended electrode having an electrode lengthsuitable for the groove G being welded. Extended electrode 32 may haveany length suitable for a given deep groove weld, including lengthsgreater than 10 millimeters. As depicted in the example shown, electrodelength may be greater than 100 millimeters. The particular example shownhas a length of about 120 millimeters. This example is not limiting aselectrodes having greater or lesser lengths may be used depending on thedepth of the groove G.

Welding torch 30 is connected to a shield gas supply 102, that providesan inert gas, such as Argon gas, to welding torch 30. Welding gas supply102 may include a container, such as a cylinder, that stores shield gasS under pressure, and delivery of shield gas S, via appropriate tubingor other conduits, may be controlled by a regulator or other controller107. A non-pressurized source may be used also with gas deliveryprovided by a pump or the like. When welding thick plates or heavy wallpipes, the weld joint design typically provides a narrow groove topermit an elongated electrode to be placed in the joint with someadjustment of the torch angle to assure a good weld created by layeringa series of weld beads upon each other until the joint is filled. Thisprocess may be referred to as narrow groove welding or deep groovewelding interchangeably throughout the following description. Narrowgroove welding is a process where successive single bead weld layers areapplied on top of one another in a narrow groove or joint. One of theconsiderations in the narrow groove environment is maintainingsufficient shield gas to protect the molten weld puddle from atmosphericcontamination. Typically, an inert shield gas, such as Argon, isprovided from outside the weld joint with a long electrode extendinginto the groove below the shield gas supply.

The welder may include a wire feeder connected to a supply of weldingwire, such as a spool 103 that provides tungsten wire W to one or morewire guides 104′, 104. In the example shown, a pair of extended wireguides 104′, 104 are provided and fed by independent spools 103 locatedon either side of chassis 101. The extended wire guides 104′, 104 aresupported on first camera device and wire guide system 105 (alsoreferred to as first mount system 105) and second camera device and wireguide system 106 (also referred to as second mount system 106)respectively that are each laterally outward of electrode 32 and abovethe workpiece or pipe P. It is to be appreciated that the support forthe extended wire guides 104′, 104 can be chosen with sound engineeringjudgment without departing from the intended scope of coverage of theembodiments of the subject invention.

The wire guides 104′, 104 can include position device (e.g., discussedbelow in FIG. 4) that provides automated or semi-automated motion,wherein the motion can be in any direction within a 3-dimensionalenvironment in proximity to an arc created within welding zone Z. Forinstance, the wire guides 104′, 104 can extend inward and downwardtoward electrode 32 and welding zone Z. The example welder is supportedon a track and drive by a tractor drive around pipe (also referred to asworkpiece W) with wire guides 104′, 104 being located in lead and lagpositions relative to welding electrode 32. In an embodiment, firstmount system 105 is coupled to height adjustment device 130 that allowsadjustment of first mount system 105 toward welding zone Z or awaywelding zone Z. It is to be appreciated that the adjustment towardwelding zone Z or away welding zone Z can be automated orsemi-automated. Further, the adjustment can be to a side of the weldingzone Z or to an opposite side of the welding zone Z (e.g., a leftmotion, a right motion, etc.). Height adjustment device 130 is furthercoupled to support member 132 that is coupled to a portion of chassis101 of welder system 100. Similarly, second mount system 106 is coupledto height adjustment device 124 that allows adjustment of second mountsystem 106 toward welding zone Z or away welding zone Z. It is to beappreciated that the adjustment toward welding zone Z or away weldingzone Z can be automated or semi-automated. Further, the adjustment canbe to a side of the welding zone Z or to an opposite side of the weldingzone Z (e.g., a left motion, a right motion, etc.). Height adjustmentdevice 124 is further coupled to support member 126 that is coupled to aportion of chassis 101 of welder system 100.

First mount system 105 supports camera device 113 and wire guide 104′,wherein both camera device 113 and wire guide 104′ are positioned to aimon or toward welding zone Z. Similarly, second mount system 106 supportscamera device 112 and wire guide 104, wherein both camera device 112 andwire guide 104 are positioned to aim on or toward welding zone Z. It isto be appreciated that system 100 includes camera device 112 and cameradevice 113 but such devices are solely illustrating various embodimentsand is not to be considered limiting on the subject innovation. It is tobe appreciated that camera device 113 and wire guide 104′ move together(or independently) with welder system 100 which enables supply ofwelding wire consistently at welding zone Z and/or where wire is feedfrom wire guide 104′. It is to be appreciated camera device 112 and wireguide 104 together (or independently) with welder system 100 whichenables supply of welding wire consistently at welding zone Z and/orwhere wire is fed from wire guide 104′ and ultimately from wire feeder(wire supply or spool 103).

FIGS. 3A and 3B illustrate diagrams of a hot wire welding system 300 anda hot wire welding system 302 in accordance with the subject innovation.As discussed above, it is to be appreciated and understood that anysuitable hot wire welder system can be implemented with the subjectinnovation and such systems in FIGS. 1-3B are not to be limiting on thescope of the subject claims. System 300 includes a first power supply310 that provides a first heat source to create an arc between anelectrode (e.g., a non-consumable electrode for instance) and aworkpiece W, wherein a puddle is created by the electrode. System 300further includes hot wire power supply 320 (e.g., welding wire powersupply) that heats a welding wire fed into a puddle formed by theelectrode. In other words, hot wire power supply 320 can energize awelding wire that is fed or delivered into the puddle to deposit weldingmaterial (e.g., liquefied welding wire) onto workpiece W. It is to beappreciated that welding systems 100 and 300 can be chosen and used withsound engineering judgment without departing from the intended scope ofcoverage of the embodiments of the subject invention.

System 302 includes a first power supply 310 that provides a first heatsource to create an arc between an electrode (e.g., a non-consumableelectrode for instance) and a workpiece W, wherein a puddle is createdby the electrode. System 300 further includes hot wire power supply 320(e.g., welding wire power supply) that heats a welding wire fed into apuddle formed by the electrode. In other words, hot wire power supply320 can energize a welding wire that is fed or delivered into the puddleto deposit welding material (e.g., liquefied welding wire) ontoworkpiece W. It is to be appreciated that welding systems 100 and 300can be chosen and used with sound engineering judgment without departingfrom the intended scope of coverage of the embodiments of the subjectinvention.

It is to be appreciated that systems 300 and 302 can be a hot wire TIGwelder system or a hot wire tandem welder system. The subject innovationcan relate to an arc that is created by any suitable wire processes,wherein such wire processes can include non-consumable electrodeprocesses.

FIG. 4 illustrates welder system 400 that manipulates an arc direction.System 400 includes wire guide 404 that directs welding wire 402 to awelding zone that includes an arc (not shown) that is generated betweenelectrode 406 and workpiece W. It is to be appreciated that wire guide404 can be any suitable member that delivers welding wire 402 from wirefeeder 430 to the welding zone. Torch 420 in system 400 includeselectrode 406 in which power source 410 creates the arc betweenelectrode 406 and workpiece W. It is to be appreciated that the arc canbe a positive (+) polarity in a GMAW welding operation and a negative(−) polarity in a GTAW welding operation.

System 400 can include welding wire power source 440 that can energizewelding wire 402, wherein the energizing of welding wire 402 is based ona current. For example, welding wire power source can generate awaveform to energize welding wire 402. Additionally, AC component 450can provide alternating current (AC) to energize welding wire 402 with apositive polarity (+) and a negative (−) polarity. It is to beappreciated that the AC component 450 can further energize welding wire402 with a waveform that include a positive (+) polarity or a negative(−) polarity. By way of example and not limitation, the arc can besteered, directed, influenced, manipulated, among others by anamplitude, width (e.g., balance) of the waveform from AC component 450.

System 400 can further include position device 470 that providesmovement to at least one of wire guide 404, welding wire 402, workpieceW, torch 420, electrode 406, or a combination thereof. Position device470 can provide movement in any direction around the arc, toward thearc, among others. By way of example and not limitation, position device470 can provide an oscillating movement, a motion to a side of the arc,a motion to an opposite site of the arc, a motion toward the arc, amotion away from the arc, a motion above the arc, a motion below thearc, or a combination thereof. In an embodiment, torch 420 includesposition device 470 that maneuvers about workpiece W. In anotherembodiment, position device 470 can change the location of workpiece Win relation to electrode 406. For instance, workpiece W can be rotatedunder/below torch 420 in, for example, an automation environment. Instill another embodiment, position device 470 can be a welder seamer. Instill another embodiment, position device 470 can be utilized with wireguide 404 and/or welding wire 402 to change a position or location atwhich welding wire is delivered to the arc. Still, position device 470and various configurations thereof can be chosen and used with soundengineering judgment without departing from the intended scope ofcoverage of the embodiments of the subject invention.

System 400 can include controller 460 that is configured to manipulate adirection of an arc created between electrode 406 (included with torch420) and workpiece W. Controller 460 can manipulate the direction of anarc based on adjusting one or more welding parameters. By way of exampleand not limitation, the welding parameter can be a polarity of weldingwire (via AC component 450), a change of location for where welding wire402 is presented to the arc (via position device 470), among others(discussed in more detail below). For example, the arc can have a firstpolarity and welding wire 402 can be energized with a second polarity,wherein the first polarity and the second polarity can be used bycontroller 460 to manipulate a direction of the arc. By way of example,an arc can be a positive (+) polarity and welding wire 402 can beenergized with a negative (−) polarity which would result in a repulsionbetween welding wire 402 and the arc. In another example, the arc can bea positive (+) polarity and welding wire 402 can be a positive (+)polarity which would result in an attraction between welding wire 402and the arc. By way of example, an arc can be a negative (−) polarityand welding wire 402 can be energized with a positive (+) polarity whichwould result in a repulsion between welding wire 402 and the arc. Inanother example, the arc can be a negative (−) polarity and welding wire402 can be a negative (−) polarity which would result in an attractionbetween welding wire 402 and the arc. In other words, a same polaritybetween welding wire 402 and the arc can draw the arc toward weldingwire 402 and a different polarity between welding wire 402 and the arccan repel the arc away from welding wire 402. When polarities aredifferent between welding wire 402 and the arc, the arc tends to bepushed away. At such time, the arc snaps (e.g., moves) to welding wire402 up and around a tip thereof. One of sound engineering judgment wouldrecognize this is based on magnetic fields. When the polarity is thesame between welding wire 402 and the arc, the magnetic fields canceleach other out between welding wire 402 and the arc. The arc is pushedby the unbalanced magnetic field toward the weak spot in the directionof welding wire 402. In an example, variable polarity can be used so thearc stays in a middle/central location in relation to electrode 406. Itis to be appreciated that a magnitude of the arc can be set by a currentgoing through electrode 406 via power source 410, wherein the magnitudeof a deflection of the arc is controlled by a magnetic field of weldingwire 402. For instance, the magnetic field of welding wire 402 can becontrolled by a current of welding wire 402 via welding wire powersource 440.

Controller 460 can adjust the polarity of welding wire 402 with awaveform from AC component 450. In addition, controller 460 can adjustthe polarity of welding wire 402 by activating and/or de-activating ACcomponent 450 which can turn the polarity of welding wire “on” or “off.”For instance, welding wire 402 can be energized with a negative (−)polarity which attracts the negative (−) polarity arc and, uponde-activation of the energizing of welding wire, polarity of weldingwire 402 changes and affects the direction of the arc. For instance,welding wire 402 can be energized with a positive (+) polarity whichrepels the negative (−) polarity arc and, upon de-activation of theenergizing of welding wire, polarity of welding wire 402 changes andaffects the direction of the arc.

In another embodiment, the electrode included with torch 420 can have apolarity. By way of example and not limitation, the polarity of the arccreated between electrode 406 and workpiece can be adjusted. Forinstance, power source 410 can include an AC component to a waveformthat creates the arc between electrode 406 and workpiece. Controller 460can synchronize or de-synchronize the polarity of welding wire 402 withthe polarity of electrode 406 and/or the arc. By synchronizing thepolarity of welding wire 402 with the polarity of electrode and/or thearc, the polarities would be the same and attract one another affectingthe direction of the arc. By de-synchronizing the polarity of weldingwire 402 with the polarity of the electrode and/or the arc, thepolarities would be the opposite and repel one another affecting thedirection of the arc.

Controller 460 can further influence the direction of the arc based on alocation of where welding wire is positioned in relation to the arc. Byway of example, position device 470 can be utilized in conjunction withcontroller 460 to change the direction of the arc. For instance, anegative (−) polarity arc and a negative (−) polarity welding wire 402will attract one another and a proximity of welding wire 402 to the arccan manipulate the direction of the arc. In such example, moving weldingwire 402 closer to the arc can increase the change of direction of thearc and moving welding wire 402 further from the arc can decrease thechange of direction of the arc. In other words, by changing the locationof where welding wire 402 is in relation to the arc can increase ordecrease the polarity affects (e.g., the attraction or repulsion basedon similar or opposite polarities between welding wire 402 and the arc).

It is to be appreciated that although one welding wire 402 and one wireguide 404 are illustrated, system 400 and the subject innovation caninclude two or more welding wires and respective wire guides. Thus,system 400 can provide independent and/or concurrent control of the twoor more welding wires and respective wire guides to manipulate thedirection of the arc. For instance, for the two or more wires, one ormore of the following can be adjusted or controlled in order toinfluence the direction of the arc: a polarity of welding wire 402; anactivation or de-activation of an energizing of welding wire 402; asynchronizing or de-synchronization of polarity between welding wire 402and the arc; and a location of welding wire 402 in relation to the arc(via position device 470). Moreover, it is to be appreciated that thearc can be a positive (+) polarity in a GMAW welding operation and anegative (−) polarity in a GTAW welding operation and the followingexamples can be implemented with either polarity for each respectivewelding operation.

It is to be appreciated and understood that system 400 can includevarious configurations and embodiments and the configuration in system400 is not to be limiting on the subject innovation. Wire feeder 430 canbe a stand-alone component (as depicted), incorporated into AC component450, incorporated into welding wire power source 440, incorporated intocontroller 460, incorporated into position device 470, incorporated intopower source 410, incorporated into torch 420, or any suitablecombination thereof. Welding wire power source 440 can be a stand-alonecomponent (as depicted), incorporated into AC component 450,incorporated into controller 460, incorporated into wire feeder 430,incorporated into position device 470, incorporated into power source410, incorporated into torch 420, or any suitable combination thereof.AC component 450 can be a stand-alone component (as depicted),incorporated into controller 460, incorporated into welding wire powersource 440, incorporated into wire feeder 430, incorporated intoposition device 470, incorporated into power source 410, incorporatedinto torch 420, or any suitable combination thereof. Position device 470can be a stand-alone component (as depicted), incorporated into ACcomponent 450, incorporated into welding wire power source 440,incorporated into wire feeder 430, incorporated into controller 460,incorporated into power source 410, incorporated into torch 420, or anysuitable combination thereof. Moreover, it is to be appreciated thatwelding wire power source 440 and power source 410 can be separatesources (as depicted), shared, a single power source, or a combinationthereof. Controller 460 can be a stand-alone component (as depicted),incorporated into AC component 450, incorporated into welding wire powersource 440, incorporated into wire feeder 430, incorporated intoposition device 470, incorporated into power source 410, incorporatedinto torch 420, or any suitable combination thereof.

FIG. 5A illustrates side view 500 of a welding operation that influencesa direction of arc 504. Side view 500 includes arc 504 that has anegative (−) polarity, wherein arc 504 is created between workpiece Wand electrode 406. Upon delivery of welding wire 402 via wire guide 404into the welding zone and ultimately a puddle formed by electrode 406,welding wire 402 is liquefied and becomes deposited welding material 506into the puddle on workpiece W to fill joint 502. Since welding wire 402is energized with a negative (−) polarity, arc 504 direction ismanipulated to attract to welding wire 402. It is to be appreciated thatdirection of arc 504 can further be manipulated by controller 460discussed above (e.g., location/movement of welding wire 402 in relationto arc 504, activation/de-activation of energizing of welding wire 402,synchronization/de-synchronization of polarities between welding wire402 and electrode 504, amplitude of waveform for energizing welding wire402, and the like). For instance, welding wire 402 can be located in lagand/or lead in relation to the direction of travel for the weldingoperation.

FIG. 5B illustrates top view 501 of a welding operation that influencesa direction of arc 504. Top view 501 includes arc 504 that has anegative (−) polarity, wherein arc 504 is created between workpiece Wand electrode 406. Upon delivery of welding wire 402 via wire guide 404into the welding zone and ultimately a puddle formed by electrode 406,welding wire 402 is liquefied and becomes deposited welding material 506into the puddle on workpiece W to fill joint 502. Since welding wire 402is energized with a negative (−) polarity, arc 504 direction ismanipulated to attract to welding wire 402. It is to be appreciated thatdirection of arc 504 can further be manipulated by controller 460discussed above (e.g., location/movement of welding wire 402 in relationto arc 504, activation/de-activation of energizing of welding wire 402,synchronization/de-synchronization of polarities between welding wire402 and electrode 504, amplitude of waveform for energizing welding wire402, and the like). For instance, welding wire 402 can be located on aside or an opposite side in relation to electrode 406. In anotherexample, welding wire 402 can be located in a lag position or a leadposition in relation to the direction of travel. Moreover, two or morewelding wires can be utilized in various locations/positions tomanipulate the direction of arc 504. It is to be appreciated that alocation of where welding wire 402 is placed in relation to electrode406 can be any suitable location (e.g., above, below, left, right, side,etc., any combination thereof).

FIG. 6A illustrates side view 600 of a welding operation that influencesa direction of arc 504. Side view 600 includes arc 504 that has anegative (−) polarity, wherein arc 504 is created between workpiece Wand electrode 406. Upon delivery of welding wire 402 via wire guide 404into the welding zone and ultimately a puddle formed by electrode 406,welding wire 402 is liquefied and becomes deposited welding material 506into the puddle on workpiece W to fill joint 502. Since welding wire 402is energized with a positive (+) polarity, arc 504 direction ismanipulated to repel from welding wire 402. It is to be appreciated thatdirection of arc 504 can further be manipulated by controller 460discussed above (e.g., location/movement of welding wire 402 in relationto arc 504, activation/de-activation of energizing of welding wire 402,synchronization/de-synchronization of polarities between welding wire402 and electrode 504, amplitude of waveform for energizing welding wire402, and the like). For instance, welding wire 402 can be located in lagand/or lead in relation to the direction of travel for the weldingoperation.

FIG. 6B illustrates top view 601 of a welding operation that influencesa direction of arc 504. Top view 601 includes arc 504 that has anegative (−) polarity, wherein arc 504 is created between workpiece Wand electrode 406. Upon delivery of welding wire 402 via wire guide 404into the welding zone and ultimately a puddle formed by electrode 406,welding wire 402 is liquefied and becomes deposited welding material 506into the puddle on workpiece W to fill joint 502. Since welding wire 402is energized with a positive (+) polarity, arc 504 direction ismanipulated to repel welding wire 402. It is to be appreciated thatdirection of arc 504 can further be manipulated by controller 460discussed above (e.g., location/movement of welding wire 402 in relationto arc 504, activation/de-activation of energizing of welding wire 402,synchronization/de-synchronization of polarities between welding wire402 and electrode 504, amplitude of waveform for energizing welding wire402, and the like). For instance, welding wire 402 can be located on aside or an opposite side in relation to electrode 406. In anotherexample, welding wire 402 can be located in a lag position or a leadposition in relation to the direction of travel. Moreover, two or morewelding wires can be utilized in various locations/positions tomanipulate the direction of arc 504. It is to be appreciated that alocation of where welding wire 402 is placed in relation to electrode406 can be any suitable location (e.g., above, below, left, right, side,etc., any combination thereof).

FIG. 7A illustrates side view 700 of a welding operation that influencesa direction of arc 504. Top view 700 includes arc 504 that has anegative (−) polarity, wherein arc 504 is created between workpiece Wand electrode 406. Upon delivery of welding wire 403 via wire guide 405into the welding zone and ultimately a puddle formed by electrode 406,welding wire 403 is liquefied and becomes deposited welding material 506into the puddle on workpiece W to fill joint 502. Additionally, wireguide 404 is provided that delivers welding wire 402 into the weldingzone and arc 504 to manipulate the direction of arc 504. Since weldingwire 402 is energized with a positive (+) polarity and welding wire 403is energized with negative (−) polarity, arc 504 direction ismanipulated to repel from welding wire 402 and be attracted to weldingwire 403. It is to be appreciated that direction of arc 504 can furtherbe manipulated by controller 460 discussed above (e.g.,location/movement of welding wire 402 and/or welding wire 403 inrelation to arc 504, activation/de-activation of energizing of weldingwire 402 and/or welding wire 403, synchronization/de-synchronization ofpolarities between welding wire 402 and/or welding wire 403 andelectrode 504, amplitude of waveform for energizing welding wire 402and/or welding wire 403, and the like). By way of example and notlimitation, welding wire 402 is located on one side of arc 504 andwelding wire 403 is located on an opposite site of arc 504. It is to beappreciated that the location of welding wire 402 and/or welding wire403 can be in a lag position or a lead position in relation to thedirection of travel. In another embodiment, a third welding wire (notshown) can be positioned in a lead position to further manipulate thedirection of arc 504 as discussed above with controller 460. Moreover,three or more welding wires can be utilized in variouslocations/positions to manipulate the direction of arc 504.Additionally, one or both of welding wires 402, 403 can be used todeposit welding material on workpiece W concurrently, independently, ora combination thereof.

FIG. 7B illustrates top view 701 of a welding operation that influencesa direction of arc 504. Top view 701 includes arc 504 that has anegative (−) polarity, wherein arc 504 is created between workpiece Wand electrode 406. Upon delivery of welding wire 402 via wire guide 404into the welding zone and ultimately a puddle formed by electrode 406,welding wire 402 is liquefied and becomes deposited welding material 506into the puddle on workpiece W to fill joint 502. Additionally, wireguide 405 is provided that delivers welding wire 403 into the weldingzone and arc 504 to manipulate the direction of arc 504. Since weldingwire 403 is energized with a positive (+) polarity and welding wire 402is energized with negative (−) polarity, arc 504 direction ismanipulated to repel from welding wire 403 and be attracted to weldingwire 402. It is to be appreciated that direction of arc 504 can furtherbe manipulated by controller 460 discussed above (e.g.,location/movement of welding wire 402 and/or welding wire 403 inrelation to arc 504, activation/de-activation of energizing of weldingwire 402 and/or welding wire 403, synchronization/de-synchronization ofpolarities between welding wire 402 and/or welding wire 403 andelectrode 504, amplitude of waveform for energizing welding wire 402and/or welding wire 403, and the like). By way of example and notlimitation, welding wire 402 is located on one side of arc 504 andwelding wire 403 is located on an opposite site of arc 504. It is to beappreciated that the location of welding wire 402 and/or welding wire403 can be in a lag position or a lead position in relation to thedirection of travel. In another embodiment, a third welding wire (notshown) can be positioned in a lead position to further manipulate thedirection of arc 504 as discussed above with controller 460. Moreover,three or more welding wires can be utilized in variouslocations/positions to manipulate the direction of arc 504.Additionally, one or both of welding wires 402, 403 can be used todeposit welding material on workpiece W concurrently, independently, ora combination thereof.

In an embodiment, the welder system is an orbital welder. In anembodiment, the following is provided: the first polarity is a negative(−) polarity, the second polarity is a positive (+) polarity, and thenegative polarity (−) repels the positive (+) polarity; the firstpolarity is a negative (−) polarity, the second polarity is a negative(−) polarity, and the negative (−) attracts the negative (−) polarity;and the first polarity is a positive (+) polarity, the second polarityis a positive (+) polarity, and the positive (+) polarity attracts thepositive (+) polarity. In an embodiment, the controller changes thedirection of the arc based on an adjustment of a location of the weldingwire in proximity to the arc. In an embodiment, the location of thewelding wire is adjusted by movement from at least one of the weldingtorch, the workpiece, a weld seamer coupled to the workpiece, or thewelding feeder. In an embodiment, the direction of the arc is influencedbased on an oscillating motion of the welding wire in proximity to thearc.

In an embodiment, a welder system can include an AC component that isconfigured to energize the welding wire with a waveform with at leastone of a negative (−) polarity or a positive (+) polarity. In theembodiment, the AC component energizes the welding wire with at leastone of a negative (−) polarity or a positive (+) polarity based on thefirst polarity or a polarity of the electrode. In an embodiment, thecontroller influences the direction of the arc based on at least one ofan activation of the AC component or a deactivation of the AC component.

In an embodiment, a system is provided that includes a second wirefeeder that provides a second welding wire to the arc and the controllerinfluences the direction of the arc with at least one of the secondpolarity or a polarity of the second welding wire. In the embodiment,the arc is at a center of a plane and the welding wire provided to thearc from the wire feeder and the second welding wire provided to the arcfrom the second wire feeder are separated by at least 180 degreesrelative to the plane. In an embodiment, the welding wire provided tothe arc from the wire feeder and the second welding wire provided to thearc from the second wire feeder are separated by at least 90 degreesrelative to the plane.

In an embodiment, the controller manipulates the direction of the arcbased on at least one of the following: an adjustment of a location ofthe welding wire relative to the arc; an adjustment of a location of thesecond welding wire relative to the arc; a change in a polarity of atleast one of the welding wire or the second welding wire; a deactivationof an energizing of at least one of the welding wire or the secondwelding wire; an activation of an energizing of at least one of thewelding wire or the second welding wire; a synchronization of a polarityof at least one of the welding wire or the second welding wire with apolarity of the electrode; or a de-synchronization of a polarity of atleast one of the welding wire or the second welding wire with a polarityof the electrode.

In an embodiment, the welder system can include a third wire feeder thatprovides a third welding wire to the arc, a fourth wire feeder thatprovides a fourth welding wire to the arc, wherein the controllerinfluences the direction of the arc with at least one of the secondpolarity, a polarity of the third welding wire, or a polarity of thefourth welding wire. In the embodiment, the controller manipulates thedirection of the arc based on at least one of the following: anadjustment of a location of the welding wire relative to the arc; anadjustment of a location of the second welding wire relative to the arc;an adjustment of a location of the third welding wire relative to thearc; an adjustment of a location of the fourth welding wire relative tothe arc; a change in a polarity of at least one of the welding wire, thesecond welding wire, the third welding wire, or the fourth welding wire;a deactivation of an energizing of at least one of the welding wire, thesecond welding wire, the third welding wire, or the fourth welding wire;an activation of an energizing of at least one of the welding wire, thesecond welding wire, the third welding wire, or the fourth welding wire;a synchronization of a polarity of at least one of the welding wire, thesecond welding wire, the third welding wire, or the fourth welding wirewith a polarity of the electrode; or a de-synchronization of a polarityof at least one of the welding wire, the second welding wire, the thirdwelding wire, or the fourth welding wire with a polarity of theelectrode.

In view of the exemplary devices and elements described supra,methodologies that may be implemented in accordance with the disclosedsubject matter will be better appreciated with reference to the flowcharts and/or methodology of FIG. 8. The methodologies and/or flowdiagrams are shown and described as a series of blocks, the claimedsubject matter is not limited by the order of the blocks, as some blocksmay occur in different orders and/or concurrently with other blocks fromwhat is depicted and described herein. Moreover, not all illustratedblocks may be required to implement the methods and/or flow diagramsdescribed hereinafter.

Sequentially, the following occurs as illustrated in the decision treeflow diagram 800 of FIG. 8 which is a flow diagram 800 that providescontrolling a direction of an arc created during a welding operation. Atreference block 810, an arc between an electrode and a workpiece can becreated. At reference block 820, a welding wire can be delivered to thearc. At reference block 830, the welding wire can be energized with acurrent. At reference block 840, a polarity of the current can beutilized to change a direction of the arc.

In an embodiment, a method includes steps of adjusting a location ofwhere the welding wire is delivered to the arc and changing thedirection of the arc based on the location. In an embodiment, a methodis provided that synchronizes (or de-synchronizes) a waveform of theelectrode and a waveform of the welding wire with a phase angle tocontrol the direction of the arc, wherein an in phase of the respectivephase angles provides more deflection in comparison to an out-of-phaseof the respective phase angles. In an embodiment, the method includessteps of controlling at least one of an activation or a deactivation ofsaid step of energizing the welding wire and changing the direction ofthe arc based on said step of controlling. In an embodiment, the methodcan include a step of changing the direction of the arc based on atleast one of synchronizing or de-synchronizing the polarity with apolarity of the arc.

The above examples are merely illustrative of several possibleembodiments of various aspects of the present invention, whereinequivalent alterations and/or modifications will occur to others skilledin the art upon reading and understanding this specification and theannexed drawings. In particular regard to the various functionsperformed by the above described components (assemblies, devices,systems, circuits, and the like), the terms (including a reference to a“means”) used to describe such components are intended to correspond,unless otherwise indicated, to any component, such as hardware,software, or combinations thereof, which performs the specified functionof the described component (e.g., that is functionally equivalent), eventhough not structurally equivalent to the disclosed structure whichperforms the function in the illustrated implementations of theinvention. In addition although a particular feature of the inventionmay have been disclosed with respect to only one of severalimplementations, such feature may be combined with one or more otherfeatures of the other implementations as may be desired and advantageousfor any given or particular application. Also, to the extent that theterms “including”, “includes”, “having”, “has”, “with”, or variantsthereof are used in the detailed description and/or in the claims, suchterms are intended to be inclusive in a manner similar to the term“comprising.”

This written description uses examples to disclose the invention,including the best mode, and also to enable one of ordinary skill in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they have structural elementsthat are not different from the literal language of the claims, or ifthey include equivalent structural elements with insubstantialdifferences from the literal language of the claims.

The best mode for carrying out the invention has been described forpurposes of illustrating the best mode known to the applicant at thetime. The examples are illustrative only and not meant to limit theinvention, as measured by the scope and merit of the claims. Theinvention has been described with reference to preferred and alternateembodiments. Obviously, modifications and alterations will occur toothers upon the reading and understanding of the specification. It isintended to include all such modifications and alterations insofar asthey come within the scope of the appended claims or the equivalentsthereof.

What is claimed is:
 1. A welder system, comprising: a welding torch thatincludes an electrode; a power source that creates an arc between theelectrode and the workpiece; a wire feeder that is connected to a supplyof welding wire to provide a welding wire to a puddle formed by theelectrode, wherein the arc is a first polarity; and a welding wire powersource that energizes the welding wire with at least one of the firstpolarity or a second polarity thereby influencing a direction of thearc; and a controller that influences a direction of the arc with atleast one of a strength or a polarity of the energized welding wire viathe welding wire power source, wherein a magnitude of the direction iscontrolled by a magnetic field of the welding wire and the magneticfield is controlled by a current in the welding wire via the weldingwire power source.
 2. The welder system of claim 1, wherein the arc iscreated from at least one of a gas metal arc welding (GMAW) in which theelectrode is a positive polarity or a gas tungsten arc welding (GTAW) inwhich the electrode is a negative polarity.
 3. The welder system ofclaim 1, further comprising at least one of following: the firstpolarity is a positive (+) polarity, the second polarity is a negative(−) polarity, and the positive (+) polarity repels the negative (−)polarity; the first polarity is a negative (−) polarity, the secondpolarity is a positive (+) polarity, and the negative polarity (−)repels the positive (+) polarity; the first polarity is a negative (−)polarity, the second polarity is a negative (−) polarity, and thenegative (−) attracts the negative (−) polarity; and the first polarityis a positive (+) polarity, the second polarity is a positive (+)polarity, and the positive (+) polarity attracts the positive (+)polarity.
 4. The welder system of claim 1, the controller changes thedirection of the arc based on an adjustment of a location of the weldingwire in proximity to the arc.
 5. The welder system of claim 4, whereinthe location of the welding wire is adjusted by movement from at leastone of the welding torch, the workpiece, a weld seamer coupled to theworkpiece, or the welding feeder.
 6. The welder system of claim 4, thedirection of the arc is influenced based on an oscillating motion of thewelding wire in proximity to the arc.
 7. The welder system of claim 1,further comprising an AC component that is configured to energize thewelding wire with a waveform with at least one of a negative (−)polarity or a positive (+) polarity.
 8. The welder system of claim 7,the AC component energizes the welding wire with at least one of anegative (−) polarity or a positive (+) polarity based on at least oneof the first polarity of the arc, the second polarity of the arc, or apolarity of the electrode.
 9. The welder system of claim 7, thecontroller influences the direction of the arc based on at least one ofan activation of the AC component or a deactivation of the AC component.10. The welder system of claim 1, further comprising: a second wirefeeder that provides a second welding wire to the arc; and thecontroller influences the direction of the arc with at least one of thefirst polarity of the arc, the second polarity of the welding wire, or apolarity of the second welding wire.
 11. The welder system of claim 10,further comprising: the arc is at a center of a plane; and the weldingwire provided to the arc from the wire feeder and the second weldingwire provided to the arc from the second wire feeder are separated by atleast one of 180 degrees or 90 degrees relative to the plane.
 12. Thewelder system of claim 1, wherein the electrode is a tungsten basedelectrode and the first polarity is DC negative.
 13. The welder systemof claim 10, the controller manipulates the direction of the arc basedon at least one of the following: an adjustment of a location of thewelding wire relative to the arc; an adjustment of a location of thesecond welding wire relative to the arc; a change in a polarity of atleast one of the welding wire or the second welding wire; a deactivationof an energizing of at least one of the welding wire or the secondwelding wire; an activation of an energizing of at least one of thewelding wire or the second welding wire; a synchronization of a polarityof at least one of the welding wire or the second welding wire with apolarity of the electrode; or a de-synchronization of a polarity of atleast one of the welding wire or the second welding wire with a polarityof the electrode.
 14. The welder system of claim 10, a third wire feederthat provides a third welding wire to the arc; a fourth wire feeder thatprovides a fourth welding wire to the arc; and the controller influencesthe direction of the arc with at least one of the second polarity, thefirst polarity, a polarity of the third welding wire, or a polarity ofthe fourth welding wire.
 15. The welder system of claim 14, thecontroller manipulates the direction of the arc based on at least one ofthe following: an adjustment of a location of the welding wire relativeto the arc; an adjustment of a location of the second welding wirerelative to the arc; an adjustment of a location of the third weldingwire relative to the arc; an adjustment of a location of the fourthwelding wire relative to the arc; a change in a polarity of at least oneof the welding wire, the second welding wire, the third welding wire, orthe fourth welding wire; a deactivation of an energizing of at least oneof the welding wire, the second welding wire, the third welding wire, orthe fourth welding wire; an activation of an energizing of at least oneof the welding wire, the second welding wire, the third welding wire, orthe fourth welding wire; a synchronization of a polarity of at least oneof the welding wire, the second welding wire, the third welding wire, orthe fourth welding wire with a polarity of the electrode; or ade-synchronization of a polarity of at least one of the welding wire,the second welding wire, the third welding wire, or the fourth weldingwire with a polarity of the electrode.
 16. A method of welding,comprising: creating an arc between an electrode and a workpiece;delivering a welding wire to a puddle formed by the electrode;energizing the welding wire with a current; and utilizing a polarity ofthe current to change a direction of the arc.
 17. The method of claim16, further comprising at least one of the following: adjusting alocation of where the welding wire is delivered to the arc and changingthe direction of the arc based on the location; or synchronizing awaveform of the electrode and a waveform of the welding wire with aphase angle to control the direction of the arc, wherein an in phase ofthe respective phase angles provides more deflection in comparison to anout-of-phase of the respective phase angles.
 18. The method of claim 16,further comprising: controlling at least one of an activation or adeactivation of said step of energizing the welding wire; and changingthe direction of the arc based on said step of controlling.
 19. Themethod of claim 16, further comprising changing the direction of the arcbased on at least one of synchronizing or de-synchronizing the polaritywith a polarity of the arc.
 20. A welder system, comprising: an orbitalwelder having a chassis supported adjacent to a workpiece; a weldingtorch coupled to the chassis that includes an electrode; a power sourcethat creates an arc between the electrode and the workpiece; a wirefeeder that is connected to a supply of welding wire to provide awelding wire to a puddle formed by the electrode, wherein the arc is afirst polarity; means for energizing the welding wire with at least oneof the first polarity or a second polarity thereby influencing adirection of the arc; means for influencing at least one of thedirection of the arc or a magnitude of the arc with at least one of astrength or a polarity of the energized welding wire; and means foradjusting a location of the welding wire in proximity to the arc.